INSULATING MULTIPLE LAYER SEALED UNITS AND INSULATING-SPACER AND ASSEMBLY

Abstract: There is described a spacer for use in connecting the edges of two or more panes of insulating glass, panel walls or the like. It is extruded in one material and is formed with retaining lips (external (90) and internal (99)). The present invention is a spacer frame with external lips to increase strength of assembly and possibility to be utilised in most of today multi-pane glazing assembly. Its body is made of Polyvinyl chloride (PVC) with appropriate mineral type filler.

Description: INSULATING MULTIPLE LAYER SEALED UNITS AND INSULATING- SPACER AND ASSEMBLY. TECHNICAL FIELD This invention relates generally to a spacer for multi-pane glazing structures, and more particularly relates to a new type of spacer for its shape and type of material used. The invention also relates to structures having exceptional thermal insulation performance by using the invention spacer. BACKGROUND / PRIOR ART Multi-pane glazing structures have been in use for some time, since they replaced single-pane windows, as thermally insulating windows, in industrial, commercial, and residential contexts. Spacers used in the glazing structures have been made of aluminium, galvanised steel, plastic, polymer, rubber and other soft or hard materials, sometimes used alone some other times combined with each others. Spacer bars are set along the periphery of the space between the panes and are typically long hollow perforated metal sections. Aluminium alloy spacers (extruded or rolled from flat strip material) are still the most utilised spacers (other popular spacers are made of galvanised steel or silicone compound), due to low cost and ease of manufacturing. In most cases the hollow interior of the spacer contains a desiccant material which absorb any moisture that may enter into the sealed unit and/or soak up any residual moisture that may have been in the enclosed air or low-conductive gas within the sealed unit. Recent increases in energy costs as well as demand for a superior product have given rise to a need for windows and other multi-pane glazing structures of even higher thermal insulation ability. To achieve what todays markets require, different kind of approaches have been taken to increase window's thermal insulation performance. Additional panes have been incorporated into laminated structure; giving approximately R-l for a single pane, R-2 for a double pane and R-3 for 3 or more panes. (Reference ASTM.) Heat-reflective, low-emissivity ("low e") coatings have been incorporated into window structure. Special multi-pane glazing structure have been developed, as for example, in U.S. Pat. No. 5,156,894 to Hood et al. (High performance, thermally insulating multi-pane glazing structure.) Low heat transfer gas have been incorporated into the window structure/To mention some; argon, krypton, nitrogen, etc.) Spacer went from steel and aluminium to lower coefficient of heat transfer material such as polymer plastic, fibre glass and rubber. (The aim was to get away from metal spacer having too high of a thermal conductivity coefficient thus causing condensation on the inner surface of the multi-pane assembly when temperature is below the dew-point.) In most case for a high increase in cost of manufacturing rendering these products hard to market. Also a problem of reinforced plastic spacers was that they generally had a different coefficient of expansion then glass generating early failure of sealed unit. More, the reinforced plastic spacers caused problem with permeability, either permitting vapour moisture to enter or filling gas to escape. Generally one spacer assembly is made of four length of spacer mechanically fastened with corner joint, inserted under pressure. Other techniques like folding around the corner with or without notching the spacer or a complete cut of the spacer after which the length of spacer are thermally weld or by other means joint together without mechanical joint. Once the panes have been put in place on each side of the spacer assembly, a sealant is applied to the outside of that particular assembly to seal and to adhere to the outermost area of the spacer frame and to the panes surfaces area facing the spacer frame and outside of it. Common sealing material used for this type of assembly are generally made of compounds subject to undergo polymerisation by catalysis. These sealant are polysulfide derivatives of the urethanes family. Polysulfide is used as a simple sealant or in combination with a primary sealant of the butyl family called poly-isobutylene. Polysulfide keeps its shape, elasticity and memory for a great temperature differential. The inventors herein postulate some reasons for the limited access of better products in the markets.(The inventors do not wish to be bound by theory and are not specialists on market survey.) Most afore mentioned method to better insulating performance of window assembly, have increased cost of manufacturing. Most of the afore mentioned method to better insulating performance of window assembly have increased cost of material. Some of the afore mentioned method to better insulating performance of window assembly have increased weight. The invention is based on the followings: to produce a spacer at low cost; improve insulation capacity of multi-pane assembly; make a spacer easy to utilised with the standard assembly techniques; and, to have a final product still adaptable to a variety of applications. The present invention addresses insulating performance; durability under extremes of temperature; better adhesion characteristics; resistance to condensation at very low temperature; strength of window assembly; cost of manufacturing;and cost of material. SUMMARY OF THE INVENTION The present invention has the primary object of providing an innovative spacer to improve insulation of multi-pane window systems of very high thermal insulation performance. It is another object of this invention to address the above noted deficiencies of the prior art. It is still another object of this invention to provide an innovative spacer which can be incorporated into multi-pane window systems and maintaining low cost of manufacturing. It is a further object of this invention to maintain low costs of material and still achieve today's need for higher insulation. Other objects, advantages and novel features of the invention spacer will be described in the following specifications and claims, and, will become apparent to those of standard skill in the art or may be learned by practice of the invention. According to the present invention part of the solution is in the extra adherence surface built in the spacer side during extrusion or by any other techniques giving the same results and also the use of polyvinyl chloride with mineral additive. Altogether giving proper mechanical specifications to utilised this invention particularly with glass in a multi-pane glazing structure comprising at least two substantially parallel sheets of glazing held in spaced relationship to each other by a peripheral spacer frame. Polyvinyl chloride with appropriate mineral filler gives excellent structural strength of assembly and good MVTR. Similar to aluminium for its mechanical qualities it facilitates precise mounting for small tolerance assembly width and a stable assembly for a large range of temperature. This invention spacer is less expensive to produce than most polymeric spacer on the market. This spacer can make a complete frame (locked in all comers) without using other parts than itself with proper cut of its surfaces. This spacer can make a complete frame at any angle without using other parts than itself with proper cut of its surfaces and by welding (catalysis, gluing or other equivalent) the locked assembly. This spacer can make a complete frame using mechanical joint for corner. This spacer can make a complete frame by welding (catalysis, gluing or other equivalent), its ends precut at any degrees. This spacer can be utilised in different type of multi-pane window assembly of high thermal insulation performance utilising special features such as low heat conductance gas or sheets of transparent plastic or other means of increasing the overall insulation quality of the assembly. DESCRIPTION OF THE DRAWINGS The invention is explained in the following text in reference to preferred embodiments which are shown here, in the accompanying drawings. DRAWINGS: FIG. 1 Shows the preferred embodiment in cross section and side view; FIG. 2A & 2B Shows two of many type of installations possible with the invention spacer; FIG. 3 Shows the invention spacer in one of his corner configuration; and FIG .4 Shows the invention spacer in two others possible corner configurations. DETAILED DESCRIPTION: For insulated spacers, the modified and improved qualities of polyvinyl chloride with mineral additive and the novel cross section shape of the invention spacer make it possible to manufacture insulated spacers resulting in five main improvements. One improvement is higher strength and stiffness of material rendering possible the novel type of side increasing the area of contact between the invention spacer and the sealant. That will be more precisely described later on in this document. It also makes it possible to lay down the spacer frame on the glass or any other type of panes and to more easily get the sides of the spacer frame parallel to the edges of the glazing sheets thus, speeding up the assembly process, as it is possible, let say, with aluminium. Another improvement is higher stability at high temperature and a long temperature range in which mechanical properties of elongation and stiffness of structure permit its easy utilisation mainly with glass . Thirdly the decrease in thermal conductivity reducing drastically the risk of condensation on the inner surface of a multi-pane assembly. A fourth improvement is continuous folded corner stability at different % and/or type of mineral filler with the use of a novel type of locking mechanism FIG.3 for ease of assembly manufacturing. Whatever the angle desired or the % and/or type of mineral filler utilised it is always possible to get a stable corner structure of the spacer frame to facilitate manufacturing of assembly. Continuous corner increase durability of the sealed unit with lower moisture vapour transmission and reduced low-conductive gas loss at the corners. A fifth improvement is a stronger structure by improving the bond between the spacer and the panes it separates by increasing the area of contact between the spacer and the sealant with a novel type spacer as shown in FIG. 1, surface 34 and more specifically area 30 and 32, where surface increase is 115% and more. A preferable increase in surface is around 150% but that is not limiting the different possible increase available with the invention spacer. The invention spacer 18A, has a hollow shape with the following areas; surface 20 being the innermost area of the assembly (FIG. 2A and 2B) in which holes 22 are made to permit humidity and water vapour in the area between the pane to be absorbed by the desiccant put in space 24 and 36; sides 26 and 28 onto which panes can be applied directly or with a layer of sealant; increased surface outermost sides areas 30 and 32 on which sealing material is applied, gives extra strength bounding between panes and the invention spacer; outermost assembly surface 34 where folding occurs for the type of corner shown in FIG. 3 and where sealant is applied when utilised in complete assembly. The longitudinal extent will be determined by the size and type of the assembly. Areas 30 and 32 are made of one, two or more recesses, these depressions or indentations in the angled surfaces 30 and 32 provide an increase in contact surface for the sealing substance chosen for the particular assembly decided by the manufacturer. These indentations or depressions can be sharp or smooth and shall not provide a place for cracks to start. Prior art use a cavity in these areas to augment the quantity of sealant and/or facilitate its application. (The surface increase in those case vary slightly around a maximum of 113 %.) The present invention attain greater increase in contact surface with the sealing material then previous spacer (115 % and above) good results being obtained at around 150 % this percentage does not limit the range covered by the invention spacer. FIG. 2A shows a cross section of a single seal, double glazed unit incorporating a hollow profile spacer 18C, in which desiccant material 58A has been placed. The spacer 18C is formed into a spacer frame as it will be explained more fully hereinafter. The preassembled spacer frame is interposed between the first glazing layer and the second glazing layer, adjacent to the periphery of the panes. The outer sealant 60 can be any sealant with good barrier properties such as hot melt butyl, polysulfide or polyurethane and so with this design because of the lower permeability of the outer sealant, there is typically not the same need or requirement for the spacer to be made from PVC with outstanding barrier properties or alternatively be coated with a separate moisture vapour and gas barrier film or coating. Though with or invention the spacer is in PVC with mineral type filler giving an excellent MVTR any humidity or water vapour left between panes 50 and 52 is absorbed by the desiccant 58A through holes 56. Sealant is applied in the outward facing channel around the periphery of the glazing sheets . The sealant must adhere to the back (FIG. 1, surfaces 30, 32 and 34) of the spacer and for certain types of compound, it may be necessary to treat, utilise a type of backing or prime the spacer to ensure good adhesion. Increased area of the surfaces 30 and 32 provide a firm connection between the sealing material and the body of the invention spacer. FIG. 2B shows a dual seal unit of a PVC with mineral filler spacer 18D. As with a conventional dual seal unit, beads or poly-isobutylene sealant 77 and 80 are applied to the sides of the hollow profile spacer 18D. Sealant 84 is applied to the outside most part of the assembly. The sealant 84 must adhere to the spacer 18D and to the panes 70 and 72. It may be necessary to treat, utilise a type of backing or prime the spacer 18D depending on the surface or the sealant utilised. Again the outer sealant 84 can be any sealant with good barrier properties such as hot melt butyl, polysulfide or polyurethane and so, with this design because of the lower permeability of the outer sealant, there is typically not the same need or requirement for the spacer to be made from PVC with outstanding barrier properties or alternatively be coated with a separate moisture vapour and gas barrier film or coating. Though with or invention the spacer is in PVC with mineral type filler giving an excellent MVTR , and any humidity or water vapour left between panes 70 and 72 is absorbed by the desiccant 58B through holes 76. FIG. 3 We show here a new type of mechanical joint not requiring any other piece of material then the extrusion itself. The extrusion is cut, punched, drilled, or by any other means prepared to have the following areas and parts. An area 92 permitting the spacer to be folded in area 94. Side 97A folds toward side 98A or vice versa. Any type of tongue 90A with any type of protrusion at the end, that can be locked in the opposite locking area 99A and 99B, or under the appropriately cut opposite folding surface 20 in the approximate areas 96 and 110 across the invention spacer, these possible locking areas made of a matching recess to the tongue protrusion. This type of locking mechanism is therefore not requiring a special area 36 at the bottom of the invention spacer 18A. Matching areas 96, 102, 110 and line 120 can be of any suitable type appropriate to the manufacturing and/or processing technique. As an example, once part 97C is attached to 98C, any corner angle is possible depending on area 92 shape, other locking area chosen (96,110,others) and tongue 90A length. FIG. 4 Shows other possible types of corner typical for that product. A length of spacer 128 cut to angle and matched to an other length of spacer 132 with the appropriate matching angle, are welded,glued or by any mean other than mechanical held together at joint 130. Two length of spacer 18E and 18F are held together in any angle by a mechanical joint 148. The following must be emphasised in summary. The embodiment of the invention herein illustrated presents a preferred form in composition thereof and should not be construed as limiting. The drawings described herein illustrate a very small sample of some of the possible design configuration where the invention spacer may be utilised to replace other type of spacer in multiple-glazed sealed units. Thus it is not limitative of all special cases and/or specific references of when the invention spacer may be utilised. It is not described herein but nonetheless important for those skilled in the art, that it is suggested that the invention spacer be used in conjunction with an appropriate sealing material to achieve required quality of the final multi-pane assembly. From all the above descriptions it will be apparent that there is thus provided a device of the character described which possess the particular features of advantages enumerated as desirable, but which, before enumerated advantages, rendering the invention susceptible of modification in its proportions, form, detail construction and arrangement of parts without deviating from the principle involved, or sacrificing any of its advantages, or modes of putting the invention into effect in any assembly. Therefore any failure to describe such aspect is also not intended to create any limitation to the present invention. Any other aspects, advantages and modifications within the scope of the invention will be apparent to those skilled in the art to which the invention pertains.

Claims: We claim: 1. An insulating spacer for interposition between glass panes, panel walls or like elements and in any layers of a multi-pane sealed unit, said body having an elongate configuration, the hollow interior having means of mechanically locking in place a tongue, made from the said body by punching, cutting, melting, or the likes, with the appropriate matching protrusion to the interior locking area extending lengthwise and/or the notched opposite surface; and the exterior thereof including opposite side surface portions having means integral therewith and projecting outwardly therefrom, which are arranged in a relatively spaced relation but not necessarily even relation, said jointing means extend lengthwise of said body providing more contact surface with any type of sealing material. 2. A spacer as claimed in claim one(l) shaped with elongated cavities, indentations, recesses or the likes uniformly spaced on the side of the body rendering the external sides of the spacer uneven with more surface for the sealing material to adhere to. From a cross section view these cavities, indentations, recesses or the likes form any type of shape resembling square waves, sinusoidal waves, saw tooth waves, random shape waves or the likes mixed together or not, increasing contact area between the spacer as claimed in claim one(l) and any type of sealing material utilised. 3. A spacer as claimed in claim two(2) where said spacer is made of Polyvinyl chloride(PVC) with mineral type filler at a percentage appropriate to the utilisation thereof. 4. A spacer as claimed in claim two(2) where a locking attachment can be made in any shape from any parts of the spacer and the internal surfaces by any means of cutting, shaping, punching, melting, drilling or the likes. 5. A spacer as claimed in claim three(3) where a locking attachment can be made in any shape from any parts of the spacer and the internal surfaces by any means of cutting, shaping, punching, melting, drilling or the likes. 6. A spacer as claimed in claim three(3) where said insulating spacer is a profile extrusion. 7. A spacer as claimed in claim three(3) where said insulating spacer is rolled form from a flat or pre-shaped strip of PVC with mineral filler. 8. A spacer as claimed in claim two(2) in which said spacer has a substantially closed shape with proper holes of any shapes instead of shaped areas, able to lock attachment made from any parts of the spacer and the internal surface as claimed in four (4). 9. A spacer as claimed in claim three(3) in which said spacer has a substantially closed shape with proper holes of any shapes instead of shaped areas, able to lock attachment made from any parts of the spacer and the internal surface as claimed in four (4). 10.A locking system as claimed in claim four(4) and eight(8) where said locking system is made of any type of material possibly utilised in this particular technical field to make a hollow spacer body. ll.A spacer as claimed in claim two(2) where said uneven external sides are made of any type of material possibly utilised in this particular technical field to make a hollow spacer body.

Inventors: BOUDREAULT JAMES, DELISLE FRANCE, BOUDREAULT, JAMES, DELISLE, FRANCE
Applicants: BOUDREAULT JAMES, DELISLE FRANCE, BOUDREAULT, JAMES, DELISLE, FRANCE
Application year: 1994
Main classification: E06B3
IPC codes: E06B3